Bitumen Emulsion Plant

What is Bitumen Emulsion Plant?

Bitumen emulsions are heterogeneous two-phase systems consisting of insoluble bitumen and water. It is produced by mixing in certain proportions and passing through a colloid mill. Vimpo Emulsion Plant VEP can be selected in the capacity range of 4 – 20 t/h. Thanks to the flow meters and scales used for each line, a mixture is obtained with precise proportions in accordance with the desired recipe.

High efficiency emulsion can be obtained with specially designed Vimpo Colloidal Mills. It provides the best mixing of bitumen and solution with its gap adjustment (0.2-3 mm),3-stage shredding design and adjustable gap mechanism. Rotor and stator discs produced with materials resistant to high temperatures, acid and water ensure the flawless operation of the Vimpo Colloidal Mill for many years.

VEP Bitumen Emulsion Plant

Vimpo Emulsion Plant, which has a specially designed emulsion mill, can be selected in the capacity range of 4 – 20 tons/hour. Thanks to the flow meters used for each line, a mixture is obtained with precise proportions in accordance with the desired recipe. Thanks to its bunkerless design, it is suitable for container type and is transported ready for use in the field.

VEP 5 Bitumen Emulsion Plant

• Production Capacity: 5 t / hour (max)
• Emulsion Mill: VIMPO VCM E-4
• Mill Capacity: 4 - 10 t / hour (max)
• Bitumen Pump: VIMPO VF72
• Bitumen Pump Capacity: 6 m³ / h@1450 rpm
• Heating: Electrical or Thermal Oil
• Solution Pump: 4 m³ / h (max)

VEP 10 Bitumen Emulsion Plant

• Production Capacity: 10 t / hour (max)
• Emulsion Mill: VIMPO VCM E-10 (Optionel Supraton Mill)
• Mill Capacity: 10 - 1 t / hour (max)
• Bitumen Pump: VIMPO VN204
• Bitumen Pump Capacity: 11 m³ / h@950 rpm
• Heating: Electrical or Thermal Oil
• Solution Pump: 12 m³ / h (max)

VEP 20 Bitumen Emsion Plant

• Production Capacity: 20 t / hour (max)
• Emulsion Mill: VIMPO VCM E-20 (Optionel Supraton Mill)
• Mill Capacity: 20 t / hour (max)
• Bitumen Pump: VIMPO VN636
• Bitumen Pump Capacity: 35 m³ / h@950 rpm
• Heating: Electrical or Thermal Oil
• Solution Pump: 18 m³ / h (max)

Bitumen Emulsion Plant Features

• VIMPO manufactured 30 Kw, 10 m3/h flowrate, adjustable space (0.2 – 3mm) collodial mill,
• VIMPO manufactured 30 Kw, 4 m3/h flowrate, adjustable space (0.2 – 3mm) collodial mill,
• VIMPO manufactured 45 Kw, 20 m3/h flowrate, adjustable space (0.2 – 3mm) collodial mill
• Stainless steel, electric heated WAE (Water + Acid + Emulgator) tank,
• Weighing system with loadcells,
• Compact and with out bunker design, acid and emulgator dosage system with flowmeter,
• Anti-foam collector,
• Container type compact design allows easy shipping and Install-Start opportunity (20’ DC container),
• PLC Control system wirh touch screen implanted on control panel,
• Optional Entegrated Bitumen Tank (EBT),
• Optional Thermal Oil Heating System.

Bitumen Emulsion Plant Turkey

Bitumen Emulsion Plant can optionally be produced with hot oil and electrical heating. Vimpo VEP Emulsion Plant has a stainless steel electrically heated WAE tank (Water-Acid-Emulsifier). Optional integrated bitumen tank and hot oil system are available. Vimpo Emulsion System has a weighing system with load cells.

Emulsion Plants has an anti-foaming collector. Vimpo Emulsion Plant provides sensitive production process and control with a PLC controlled system inside an easily accessible control panel. Thanks to the easy-to-use touch screen on the control panel, the production process can be observed and controlled.

Thanks to the Vimpo Emulsion Plant dosing feature and the flow meters used to load the acid and emulsifier into the tank, the bunker is eliminated and a more compact design is obtained.

Bitumen Emulsion Plant has a compact and bunker-free, stainless, acid and emulsifier dosing system with flowmeter. Vimpo Vep Emulsion Plant has a compact container type design that provides easy transportation and setup. (Possibility of shipping with 40' DC container).

Vimpo brand bitumen pump works silently with high efficiency. The pump provides uninterrupted transfer with a flow rate of 50 m3/h. The bitumen pump produced by VIMPO works in full harmony with the valves and filters produced by VIMPO. Mechanical seals used in the pump offer excellent performance against impermeability.

VEP 20 Emulsion Plant has 2 WAE tanks (Water-Acid-Emulsifier-). Vimpo VEP 4 Emulsion Facility has an optional manual system option. VEP Emulsion Facilities are designed in accordance with longlasting, operator-friendly and high efficiency standards.

How To Use The VEP Vimpo Emulsion Plant

Bitumen Emulsion Plant emergency stops in the facility are automatically controlled by the automation system and if there is no emergency, the control phase is activated throughout the facility. The valve that allows the produced emulsion to be sent to the stock tank or to the distributor is opened. After these processes are done, material preparations must be made in order to start production. Filling the water into the tank and heating it to the desired temperature, heating the mill-pump-bitumen line-filter are carried out. Bitumen pump temperature and tolerance value and start and stop time settings (hour/minute) of heaters, if any, are made. According to these settings and parameters, the heaters will automatically turn on and off. These adjusted values are saved in permanent memory.

The heaters should not be operated when the tank is completely empty. The heaters will be activated after seeing a minimum of 500 kg of water in the tank.

Bitumen Emulsion Plant is heated with automatically controlled electric heaters. After the bitumen pump-mill and bitumen line heaters in the emulsion facility are started, water is taken to the facility. The desired amount of water is taken into the solution tank and the pump is stopped. By operating the water tank electric heaters, the process of heating the water to the desired temperature can be started. After the water reaches the desired temperature value, the preparation of the solution to be used in the emulsion production is started.

The system automatically acts according to the bitumen and solution amounts in the selected recipe values and the tolerance values and working parameters defined by the user. When automatic production is activated, production should continue until the empty weight value of the bitumen or solution tank. Automatic emulsion production processes are performed and controlled sequentially by the automation program; Verify that at least one of the emulsion drain valves (tank or sprayer) is selected and open.

Then the mill is started. About 10 seconds after the mill is fully activated, the WAE pump is started. Then the bitumen pump is started. Bitumen and solution pumps speed values are adjusted according to recipe set values and tolerance values. The ratio between bitumen and solution is ensured continuously during production. If there is a decrease in the amount of instant solution, the amount of bitumen is reduced at that rate, or if there is a decrease in the amount of bitumen, the amount of solution is reduced at that rate.

When the weight value of the solution in the WAE tank reaches the tank empty weight value specified on the calibration page, the bitumen pump stops. 20 seconds after the bitumen pump stops, the WAE pump stops and then the mill stops. After the mill stops, the system exits the automatic production mode. As a second method, emulsion production can be done manually with the operator control of the Vimpo Emulsion Plant.

Manual emulsion production processes are performed and controlled sequentially by the operator; verify that at least one of the emulsion drain valves (tank or sprayer) is selected and open. The mill is operated. 30 seconds after the mill is fully activated, the WAE pump is started. Bitumen pump starts 60 seconds after WAE Pump starts. Speed values of bitumen and solution pumps are adjusted according to recipe set values and tolerance values.

The ratio between bitumen and solution is maintained continuously during production. If there is a decrease in the amount of instant solution, the amount of bitumen is reduced at that rate, or if there is a decrease in the amount of bitumen, the amount of solution is reduced at that rate.

These processes continue until one of the tanks reaches the empty weight value of the tank. When one of the tanks is completely empty, the bitumen pump is stopped. 60 seconds after the bitumen pump stops, the WAE pump is stopped. The mill is stopped 30 seconds after the WAE pump stops. After the emulsion production is finished, the mill should be cleaned with water.